Method of producing molecular composite material including rigid aromatic polymer

Abstract: A molecular composite material having excellent properties such as mechanical strength, heat resistance, solvent resistance, etc. is produced by dissolving a prepolymer of a rigid aromatic polymer in a monomer of a matrix polymer to form a homogeneous solution and then heating the homogeneous solution to cause a ring closure reaction of the prepolymer and a polymerization reaction of the monomer.

Description: The present invention relates to a method of producing a molecular composite material comprising a rigid aromatic polymer and a matrix polymer, and more particularly to a method of producing a molecular composite material having excellent dispersibility, mechanical strength, etc. substantially without using a solvent. Recently, to achieve the reduction of weight of aircraft, automobiles, etc., plastic materials called "engineering plastics" having excellent mechanical properties, heat resistance, etc. have been increasingly used. Apart from this, development has been actively carried out to provide composite materials such as FRPs consisting of plastic materials and high-strength, high-modulus fibers such as carbon fibers, and these composite materials are being used in many applications. It is known that the strength of these composite materials largely depends not only on the strength of plastics and reinforcing fibers but also on the interfacial bonding strength of the fibers to the matrix resins. Also, the impregnating capability of matrix resins into the fiber-reinforced preforms affects the ease of production of composite materials and the strength of the resulting products. Accordingly, even though high-strength, high modulus fibers and resins are used as starting materials, composite materials having excellent strength are not necessarily obtained. Under such circumstances, proposals have been made to develop high-strength polymer blend composites (molecular composite materials) by finely dispersing rigid polymers such as aromatic polyamides, etc. in matrix resins to a molecular level. Aromatic polymers suitable for molecular composite materials include those containing heterocyclic repeating units such as thiazole rings, imidazole rings, oxazole rings, oxazinone rings, etc. Among them, aromatic polythiazole having a thiazole ring is highly promising because of its excellent mechanical strength. In the meantime, the homogeneous dispersion of a reinforcing polymer in a matrix polymer cannot be achieved if the reinforcing polymer is simply blended with the matrix polymer. This means that simple blending fails to provide a molecular composite material having excellent mechanical properties. Therefore, various attempts have been made so far. For instance, Japanese Patent Laid-Open No. 1 287167 discloses a method of producing a polymer composite comprising the steps of introducing a polymer solution mainly containing (A) a reinforcing polymer consisting of polythiazole having a substantially rod-shaped skeleton and (B) a fusible matrix polymer into a solidification bath, and forming it into a film, the above polymer solution showing an optical anisotropy and being solidified via an apparent, optically isotropic phase after immersion in the solidification bath. Japanese Patent Publication No. 2-7976 discloses a polymer composition comprising (a) a reinforcing polymer A consisting of polythiazole having a substantially rod-shaped skeleton, and (b) a matrix polymer B consisting of a less crystallizable aromatic copolyamide having a glass transition temperature of 200°C or higher and a flow-initiation temperature of 500°C or lower, the weight ratio of A/(A + B) being 0.15-0.70. When the aromatic copolyamide is kept at a temperature between its glass transition temperature and its flow-initiation temperature for an arbitrary period of time within 5 hours, the resulting crystals have apparent sizes of 2.5 nm or less. However, in the methods of producing polymer composites as disclosed in Japanese Patent Laid-Open No. 1-287167 and Japanese Patent Publication No. 2-7976, homogeneous dispersions of the reinforcing polymers in matrix polymers are not xpected. This means that the resulting molecular composite materials do not show largely improved mechanical strength, etc. This appears to be due to the fact that the rigid reinforcing polymers and the matrix polymers do not show good compatibility with each other, leading to poor dispersibility therebetween. Thus, proposals have been made to provide a method of producing a molecular composite material of a rigid aromatic polymer, the method comprising the steps of homogeneously mixing a prepolymer of the rigid aromatic polymer and a matrix polymer or its prepolymer in an organic solvent, removing the organic solvent and then heating it so that the rigid aromatic polymer is formed from its prepolymer by a ring closure reaction (see Japanese Patent Laid-Open Nos. 64-1760 and 64-1761). Another proposal has also been made of a method of producing a molecular composite material, in which hydrogen atoms of thiol groups of an aromatic polythiazole prepolymer are substituted with alkyl groups to enhance the dispersibility of the aromatic polythiazole in a solvent (see Japanese Patent Laid-Open No. 4-114062). By the above methods, molecular composite materials having relatively good mechanical strength, etc. can be produced. However, these molecular composite materials fail to show sufficiently high dispersibility of the rigid aromatic polymer in the matrix polymer so that the molecular composite materials cannot have a sufficient mechanical strength. Accordingly, there is still a need for a method of producing a molecular composite material having excellent mechanical strength, interdispersibility of rigid polymer and matrix polymer, etc. As a result of intense research it has now been found that a molecular composite material containing the rigid aromatic polymer homogeneously dispersed in the matrix polymer can be obtained by dissolving a prepolymer of a rigid aromatic polymer in a liquid monomer of a matrix polymer and heating the mixture to cause a ring closure reaction of the prepolymer and a polymerization reaction of the monomer. Thus, viewed from one aspect the invention provides a method of producing a molecular composite material comprising a rigid aromatic polymer having at least one condensed ring selected from the group consisting of a thiazole ring, an imidazole ring, an oxazole ring, an oxaxinone ring, an imidazolebenzo-pyrrolone ring and an imidazolebenzophenanthroline ring and a matrix polyamide or copolyamide, said method comprising the steps of: (a) dissolving a prepolymer of said rigid aromatic polymer in a monomer of said matrix polyamide or copolyamide to form a homogeneous solution without the use of an organic solvent, wherein the weight ratio of said prepolymer to said monomer being in the range of 0.1/99.9 to 50/50 and the monomer of said matrix polyamide or copolyamide is at least one selected from the group consisting of ε-caprolactam, ζ-enantholactam, ω-caprylolactam, ω-decanolactam, ω-laurolactam, α-pyrrolidone and α-piperidone; and (b) heating said homogeneous solution at 200-300°C to cause a ring closure reaction of said prepolymer and a polymerization reaction of said monomer simultaneously, thereby forming said rigid aromatic polymer and said matrix polyamide or copolyamide. Prepolymer of Rigid Aromatic Polymer In the method of the invention a prepolymer of the rigid aromatic polymer is subjected to a ring closure reaction to form a rigid aromatic polymer. The rigid aromatic polymer has aromatic rings in a main chain thereof and condensed rings bonded to one or both sides of such aromatic rings. The rigid aromatic polymer has at least one condensed ring selected from the group consisting of a thiazole ring, an imidazole ring, an oxazole ring, an oxaxinone ring, an imidazolebenzopyrrolone ring and an imidazolebenzophenanthroline ring. Such a rigid aromatic polymer may be not only a homopolymer with a repeating unit containing the condensed rings but also a copolymer having such a repeating unit. (a) Prepolymer of Rigid Aromatic Homopolymer The rigid aromatic homopolymers will generally have the condensed rings constituted by carbon atoms, and one or more of nitrogen atoms, oxygen atoms and sulfur atoms. Suitable such condensed rings include thiazole rings, imidazole rings, oxazole rings, oxazinone rings, etc. The following are examples of rigid aromatic homopolymers containing such condensed rings: (1) Polybenzothiazole of formula: (2) Polybibenzothiazole of formula: (3) Polybenzoxazole of formula: (4) Polybibenzoxazole of formula: (5) Polybenzimidazole of formula: (6) Polybibenzimidazole of formula: (7) Polybibenzoxazinone of formula: (8) Polybenzimidazolebenzopyrrolone of formula: (9) Polybenzimidazolebenzophenanthroline of formula: etc. (where n is a positive integer). Among them, aromatic polythiazoles containing thiazole rings such as polybenzothiazole, polybibenzothiazole, etc. are preferred. In the discussion below, aromatic polythiazoles are used as non-limiting examples of the rigid aromatic homopolymer. The aromatic polythiazole prepolymer can be obtained by polymerizing an alkyl group-substituted aromatic diaminodithiol compound with a dicarboxylic acid. Specifically, the aromatic polythiazole prepolymer may be produced by the following steps: (1) Reacting a salt of an aromatic diaminodithiol compound with an alkyl halide in an alkaline aqueous solvent, so that hydrogen atoms of thiol groups of the aromatic diaminodithiol compound are substituted by alkyl groups; and (2) Polymerizing the monomer obtained in step (1) with a dicarboxylic acid derivative to form the aromatic polythiazole prepolymer. The above steps will be explained below. Step (1) The aromatic diaminodithiol compound is a compound having amino groups and thiol groups on both sides of its aromatic residual group, and the aromatic residual group may be not only a benzene ring but also any aromatic ring in which 2 or more benzene rings are condensed. Further, the aromatic residual group may be a group having 2 or more benzene rings bonded to each other, such as biphenyl. The amino groups and the thiol groups on both sides may be bonded to the aromatic residual group symmetrically with respect to its axis or its central point. Typical examples of such aromatic diaminodithiol compounds are: etc. These aromatic diaminodithiol compounds may be used in the form of a salt such as a hydrochloride to prevent their deterioration. The alkyl groups bonded to the thiol groups of the aromatic diaminodithiol compound in step (1) are substituted or unsubstituted alkyl groups (eg C 1-6 alkyl groups). The unsubstituted alkyl groups include an isopropyl group, an ethyl group, an n-propyl group, an n-butyl group, a sec-butyl group, a tert-butyl group, etc. Among them, secondary or tertiary alkyl groups are particularly preferable. The substituted alkyl groups may for example be the above described alkyl groups substituted with a carboxyl group, an ester group, a cyano group, a benzyl group, a halogen group, a nitro group, etc. Incidentally, in the case of having such substituent groups, the alkyl groups need not be secondary ones. The substituted alkyl groups include specifically: -CH 2 CH 2 COOCH 3 -CH(CH 3 )COOCH 3 -CH 2 CH 2 CN -CH(CH 3 )CN -CH 2 CH 2 COOH -CH(CH 3 )COOH etc. In the case of ester-substituted alkyl groups, the alkyl groups bonded to the ester group need not be methyl groups by may be longer linear alkyl groups. To bond the above alkyl group to the thiol group, the alkyl group is used in the form of a halide, namely an alkyl halide. The halides which may be used in the present invention are bromides, chlorides, iodides, etc. of the above alkyl groups. The alkaline aqueous solvent used may be water or a mixture of water and alcohol (ethanol and/or methanol) in which an alkaline salt such as sodium hydroxide is dissolved. The alkali concentration in the alkaline aqueous solvent is preferably 30 weight % or less. The substitution reaction can be conducted at a temperature of 0-100°C. The reaction time is not specifically restricted, but it is generally about 2-24 hours. To accelerate the substitution reaction, the solution is preferably stirred. Also, by using an excess amount of an alkyl halide, the reaction rate and yield can be increased. When the substitution reaction is performed under the conditions described above, hydrogen atoms of thiol groups of the aromatic diaminodithiol compound can be substituted with alkyl groups, thereby obtaining a desired alkyl-substituted aromatic diaminodithiol compound as a monomer. Step (2) The dicarboxylic acid derivatives used in the present invention include those having carboxylic groups substituted as follows: etc. One dicarboxylic acid derivative or a combination of two or more dicarboxylic acid derivatives may be used as desired. The residual groups of the dicarboxylic acid derivatives are preferably aromatic groups, and specific examples are as follows: etc. The most preferred example of such dicarboxylic acids is 2-chloroterephthalic acid. In the polymerization reaction of step (2), solvents such as N-methyl-2-pyrrolidone, hexamethyl phosphoric triamide, N,N-dimethylacetamide, etc. may be used alone or in combination. To increase solubility, chlorides such as LiCl, CaCl 2 , etc. may be added in an amount up to 10%. The monomer obtained in step (1) and the dicarboxylic acid derivative are dissolved in the above-described solvent in an equimolar ratio, and subjected to a polymerization reaction at a temperature ranging from -20°C to +50°C. The monomer concentration is preferably about 0.1-2 mol/liter. The solution is preferably stirred to increase the polymerization reaction rate. The polymerization reaction time is not particularly restricted, but it is generally about 1-24 hours. By performing the polymerization reaction under these conditions, an aromatic polythiazole prepolymer having a large degree of polymerization can be obtained without causing a ring closure reaction. The resulting aromatic polythiazole prepolymer may be washed and dried by a known method. The aromatic polythiazole prepolymer obtained by polymerizing the alkyl group substituted aromatic diaminodithiol compound and the dicarboxylic acid derivative may be represented by the following formula: wherein Ar 1 and Ar 2 represent aromatic residual groups. In the discussion above, an aromatic polythiazole prepolymer is used as one example of a prepolymer of the rigid aromatic homopolymer. However, other rigid aromatic homopolymers such as those enumerated above may also be used in the form of prepolymers having condensable groups which have not been subjected to a ring closure reaction (see Japanese Patent Laid Open No. 64-001761). (b) Prepolymer of Rigid Aromatic Copolymer One example of a prepolymer of a rigid aromatic copolymer (hereinafter referred to as a "precopolymer") is a prepolymer of an aromatic heterocyclic random copolymer expressed by the following formula: wherein Ar and Ar' are aromatic residues, R is a substituted or unsubstituted alkyl group, X is a residue of the dicarboxylic acid derivative, and "m" and "n" are positive integers having a ratio (m/n) of from 0.01/99.99 to 99.99/0.01. (Again polythiazoles are used here by way of nonlimiting example; analogous formulae to the one written above can be used for precopolymers for polymers having the other condensed ring systems). The precopolymer may be produced from (a) an aromatic diaminodithiol compound having thiol groups whose hydrogen atoms are substituted by substituted- or unsubstituted-alkyl groups, (b) an aromatic diamino compound and (c) a dicarboxylic acid derivative. The aromatic diaminodithiol compounds (a) having thiol groups whose hydrogen atoms are substituted by substituted- or unsubstituted-alkyl groups include those used in the production of the rigid aromatic homopolymers mentioned above and can be synthesized by the same method. The aromatic diamino compounds (b) used are preferably aromatic diamino compounds having flexible (soft) structures. Suitable aromatic diamino compounds include diamines having aromatic residues such as diphenylether, biphenyl, etc. Specific examples of the aromatic diamino compounds (b) include diamines having aromatic residues expressed by the following formulae: etc. Suitable dicarboxylic acid derivatives include those used in the production of the rigid aromatic homopolymers mentioned above. Once again, the dicarboxylic acid derivatives may be used alone or in combination. The method of producing the precopolymer is described in detail below. The aromatic diaminodithiol compound (a), the aromatic diamino compound (b) and the dicarboxylic acid derivative (c) are dissolved in desired proportions in an organic solvent to cause their copolymerization reaction. Preferably, the aromatic diaminodithiol compound (a) and the aromatic diamino compound (b) are first dissolved in the organic solvent to prepare a homogeneous solution to which the dicarboxylic acid derivative is then added. The ratio of the concentration of the aromatic diaminodithiol compound (a) to that of the aromatic diamino compound (b) in an organic solvent is identical to the ratio of rigid chain moieties to flexible (soft) chain moieties in the aromatic heterocyclic random copolymer, namely the m/n ratio mentioned above. Accordingly, the concentrations of the aromatic diaminodithiol compound (a) and the aromatic diamino compound (b) to be used may be selected according to the intended application for the aromatic heterocyclic random copolymers. In the present invention, the compounds (a) and (b) are preferably mixed in such proportions that the ratio (m/n) is in the range of 0.01/99.99-99.99/0.01. The molar amount of the dicarboxylic acid derivative (c) will generally be identical to or greater than a total molar amount of the aromatic diaminodithiol compound (a) and the aromatic diamino compound (b). On the other hand, the total concentration of the aromatic diaminodithiol compound (a), the aromatic diamino compound (b) and the dicarboxylic acid derivative (c) in the organic solvent is preferably in the range of about 0.1-2 mol/liter. The organic solvents used may be the same as in the production of the rigid aromatic homopolymers. In the production of the precopolymer from the aromatic diaminodithiol compound (a), the aromatic diamino compound (b) and the dicarboxylic acid derivative (c), the polymerization temperature is preferably from -20°C to +50°C. In the polymerization reaction, the solution is preferably stirred to increase the polymerization reaction rate. The polymerization reaction time is not particularly restricted, but it is generally about 1-24 hours. By performing the polymerization reaction under the above conditions, an aromatic polythiazole prepolymer having a large degree of polymerization can be obtained without causing a ring closure reaction. The resulting precopolymer has an intrinsic viscosity η inh of about 1.0-1.8 (in N-methyl-2-pyrrolidone at 30°C). The resulting precopolymer may be washed and dried by a known method. With respect to the details of the precopolymer, reference may be made to Japanese Patent Laid-Open No. 4-351637. [2] Monomers of Matrix Polymers The monomers of the matrix polymers used in the present invention (hereinafter referred to as "matrix monomers") are compounds capable of dissolving the rigid aromatic prepolymers mentioned above and having a high compatibility with the rigid aromatic polymers. Matrix monomers satisfying such requirements can form aliphatic or aromatic polyamides or copolyamides and are selected from ε-caprolactam,ζ-enantholactam, ω-caprylolactam, ω-decanolactam, ω-laurolactam, α-pyrrolidone, α-piperidone, etc. These matrix monomers may be used alone or in combination. Among the aliphatic polyamides, nylon-6 is particularly preferred. These polyamides have good compatibility with prepolymers of the rigid aromatic polymers, thereby producing molecular composite materials with excellent mechanical strength. The weight ratio of the rigid aromatic polymer to the matrix polymer is in the range of 0.1/99.9 to 50/50. When the proportion of the rigid aromatic polymer as a reinforcing polymer is too high, the density of the rigid aromatic polymer in the molecular composite material becomes so high that the rigid aromatic polymer is likely to be partially aggregated, leading to poor dispersion of the rigid aromatic polymer at a molecular level and deteriorated mechanical strength of the molecular composite material. The weight ratio of the rigid aromatic polymer to the matrix polymer is more preferably in the range of 1/99 to 20/80, particularly 1/99 to 10/90. [3] Production of Molecular Composite Material The rigid aromatic prepolymer is homogeneously dissolved in the liquid matrix monomer. This may require the monomer to be melted by heating and in this case, the matrix monomer is preferably heated at 68-200°C. When the temperature is lower than 68°C, the monomer may not be adequately liquid. On the other hand, when the temperature exceeds 200°C, the monomer is likely to polymerize. Melting of the monomer is preferably conducted in an atmosphere of an inert gas such as nitrogen, argon, etc. or under a reduced pressure. A polymerization catalyst may be added to the homogeneous solution of the rigid aromatic prepolymer and the matrix monomer. Suitable polymerization catalysts include water, ε-aminocaproic acid, etc. Where water is used as the catalyst, the proportion of water used is generally 0.1-40 weight % based on the total amount of the homogeneous solution. Where ε-aminocaproic acid is used as the catalyst, its proportion is generally not greater than 40 weight %. Furthermore, phosphoric acid may be added to the solution to accelerate the polymerization of the matrix monomer. In this case, the proportion of the phosphoric acid added is generally not greater than 10 volume %. Next, the homogeneous solution is heated to 200-300°C to subject the rigid aromatic prepolymer to a ring closure reaction (formation of a condensed ring) while polymerizing the matrix monomer. When the temperature is lower than 200°C, the ring closure reaction of the rigid aromatic prepolymer and the polymerization reaction of the matrix monomer do not take place. On the other hand, when the temperature exceeds 3000C, undesirable decomposition of the matrix polymer may be initiated. The preferred temperature range is 230-280°C. The heating of the homogeneous solution may be effected not only at a constant temperature but also by elevating the temperature stepwise. Furthermore, heating is preferably effected in an atmosphere of an inert gas such as nitrogen, argon, etc. or in vacuo. By the heating process, the rigid aromatic prepolymer is subjected to the ring closure reaction. For instance, when an aromatic polythiazole prepolymer is used, the alkyl groups (R) are removed from the precopolymer, thereby forming a thiazole ring at that site. As a result, aromatic polythiazole having the following formula is obtained: wherein Ar 2 represents an aromatic residue. The ring closure reaction of the rigid aromatic prepolymer takes place simultaneously with the polymerization reaction of the matrix monomer. The rigid aromatic polymer and the matrix polymer thus obtained are dispersed mutually uniformly at a molecular level, thereby forming a molecular composite material having excellent mechanical properties. The present invention will now be described in more detail by reference to the following non-limiting Examples: Example 1 0.51 g of a polybenzothiazole prepolymer (hereinafter referred to as "PBT prepolymer") having the structure shown below (η inh =1.5 at 0.5 g/dl and at 30°C) and 30 g of liquid ε-caprolactam were placed in a reaction vessel and heated at 110°C for about 12 hours in an argon atmosphere to obtain a homogeneous solution of the PBT prepolymer in the liquid ε-caprolactam. After the PBT prepolymer was completely dissolved in the liquid ε-caprolactam, 6g of a 50-weight-% aqueous solution of aminocaproic acid as a catalyst was added to the homogeneous solution. The solution was heated to 270°C and stood for 4 hours in an argon atmosphere to subject the PBT prepolymer to a thiazole ring closure reaction and simultaneously polymerize the liquid ε-caprolactam to produce nylon-6. After cooling and solidifying at ambient temperature, the reaction product was removed from the reaction vessel and pulverized. The pulverized reaction product was refluxed with water overnight, filtered and dried at 100°C in vacuo to obtain a pellet-like molecular composite material of 1 weight % of PBT and nylon-6. 2g of the resulting pellet-like PBT/nylon-6 molecular composite material was compression-molded at 230°C and 60 kg/cm 2 to obtain a sample plate of 15 mm x 50 mm x 2 mm. The sample plate was subjected to a three point bending test to measure a bending strength and a flexural modulus according to JIS K7203. The measurement results are shown in Table 1. Furthermore, 0.1 g of the pellet-like PBT/nylon-6 molecular composite material was dissolved in 20 ml of m-cresol and the intrinsic viscosity η inh thereof at 30°C was measured according to a capillary method. The results are also shown in Table 1. Example 2 1.5 g of the same PBT prepolymer as in Example 1 and 30 g of liquid ε-caprolactam were placed in a reaction vessel and heated at 110°C for about 12 hours in an argon atmosphere to homogeneously dissolve the PBT prepolymer in the liquid ε-caprolactam. After the PBT prepolymer was completely dissolved in the liquid ε-caprolactam, 12 g of a 50 weight % aqueous solution of ε-aminocaproic acid as a catalyst was added to the homogeneous solution, heated to 270°C and stood for 7 hours in an argon atmosphere to subject the PBT prepolymer to a thiazole ring closure reaction and simultaneously polymerize the liquid ε-caprolactam to produce nylon-6. After cooling and solidifying at ambient temperature, the reaction product was removed from the reaction vessel and pulverized. The pulverized reaction product was refluxed with water overnight, filtered and dried at 100°C in vacuo to obtain a pellet-like molecular composite material of 3 weight % of PBT and nylon-6. 2g of the resulting pellet-like PBT/nylon-6 molecular composite material was molded in the same manner as in Example 1 to obtain a sample plate of 15 mm x 50 mm x 2 mm. The sample plate was subjected to a three point-bending test to measure a bending strength and a flexural modulus according to JIS K7203. The measurement results are shown in Table 1. Further, 0.1 g of the pellet-like PBT/nylon-6 molecular composite material was dissolved in 20 ml of m-cresol to measure an intrinsic viscosity η inh thereof at 30°C according to a capillary method. The results are also shown in Table 1. Comparative Example 1 30 g of ε-caprolactam was put in a reaction vessel and heated at 110°C in an argon atmosphere. 6 g of a 50-weight-% aqueous solution of ε-aminocaproic acid as a catalyst was added to ε-caprolactam. The mixture was heated to 270°C and stood for 4 hours in an argon atmosphere to subject ε-caprolactam to a polymerization reaction to produce nylon-6. The reaction product was cooled and solidified at ambient temperature. Thereafter, the reaction product was removed from the reaction vessel and pulverized. The pulverized reaction product was refluxed with water overnight. After filtering, the product was dried at 100°C in vacuo to obtain a pellet-like nylon-6. The resulting pellet-like nylon-6 was compression-molded under the same conditions as in Example 1 to obtain a sample plate of 15 mm x 50 mm x 2 mm. The sample plate was subjected to a three point-bending test to measure a bending strength and a flexural modulus according to JIS K7203. The measurement results are shown in Table 1. Furthermore, 0.1 g of the pellet-like nylon-6 was dissolved in 20 ml of m-cresol and the intrinsic viscosity η inh thereof at 30°C was measured according to a capillary method. The results are also shown in Table 1. No. Bending Strength (kgf/mm 2 ) Flexural Modulus (kgf/mm 2 ) Intrinsic Viscosity (η inh ) Example 1 13 430 0.8 Example 2 13 499 0.8 Comparative Example 1 9 251 1.02 As is clear from Table 1, the molecular composite materials of Examples 1 and 2 exhibit improved bending strength and flexural modulus, as compared with nylon-6 of Comparative Example 1. Further, in the molecular composite material of the present invention the rigid aromatic polymer is well dispersed in the matrix polymer. As described above in detail, according to the present invention, since a rigid aromatic prepolymer is dissolved in a matrix monomer and thereafter the rigid aromatic prepolymer is subjected to a ring closure reaction while polymerizing the matrix monomer, a molecular composite material having the rigid aromatic polymer well dispersed in a matrix polymer and showing an excellent mechanical strength is obtained. Since a solvent is not used in this process, there is no need of a solvent-removing step, making the production time extremely short. The molecular composite materials obtained according to the present invention have excellent properties such as mechanical strength, heat resistance, solvent resistance, etc., so that they can be used widely for automobile parts, aircraft parts, space equipment, etc.

Claims: A method of producing a molecular composite material comprising a rigid aromatic polymer having at least one condensed ring selected from the group consisting of a thiazole ring, an imidazole ring, an oxazole ring, an oxaxinone ring, an imidazolebenzopyrrolone ring and an imidazolebenzophenanthroline ring and a matrix or copolyamide, said method comprising the steps of: (a) dissolving a prepolymer of said rigid aromatic polymer in a monomer of said matrix polyamide or copolyamide to form a homogeneous solution without the use of an organic solvent, wherein the weight ratio of said prepolymer to said monomer being in the range of 0.1/99.9 to 50/50 and the monomer of said matrix polyamide or copolyamide is at least one selected from the group consisting of ε-caprolactam, ζ-enantholactam, ω-caprylolactam, ω-decanolactam, ω-laurolactam, α-pyrrolidone and α-piperidone; and (b) heating said homogeneous solution at 200-300°C to cause a ring closure reaction of said prepolymer and a polymerization reaction of said monomer simultaneously, thereby forming said rigid aromatic polymer and said matrix polyamide or copolyamide. The method according to claim 1, wherein said monomer is melted by heating, and said prepolymer is dissolved in the molten monomer to form said homogeneous solution. The method according to claim 2, wherein said monomer of said matrix polymer is heated at 68-200°C. The method according to claim 2 or 3, wherein said monomer of said matrix polyamide or copolyamide is heated in an inert gas atmosphere. The method according to any one of claims 1 to 4, wherein the heating of said homogeneous solution cause said reactions is effected in the presence of a polymerization catalyst. The method according to claim 5, wherein said polymerization catalyst is selected from the group consisting of water and ε-aminocaproic acid.

Inventors: AKITA HIROSHI, HATTORI TATSUYA, KAGAWA KAZUHIRO, KOBAYASHI HIROTO, AKITA, HIROSHI, HATTORI, TATSUYA, KAGAWA, KAZUHIRO, KOBAYASHI, HIROTO
Applicants: HONDA MOTOR CO LTD, HONDA GIKEN KOGYO KABUSHIKI KAISHA
Application year: 1994
Main classification: C08L77
IPC codes: C08L77, C08G73, C08G75, C08L79